Acoustic Sensor Array for Flotation Level Measurement
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Solution Overview
Problem
Current measurement technologies for slurry/pulp levels in flotation cells face challenges such as froth buildup, density changes, and dielectric variations, leading to inaccurate readings and high maintenance costs, particularly in mining applications where human error and operator intervention are costly and unreliable.
Innovation Solution
A sensor system utilizing arrays of acoustic transducers that generate and receive signals to determine the levels and properties of substances in a flotation tank, including a self-cleaning mechanism to prevent buildup and maintain accuracy, allowing for precise measurement of slurry/pulp, froth, and air layers without relying on dielectric constants or density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If displacement float is used to measure slurry/pulp level, then level measurement is obtained, but mechanical wear occurs at high rate and float sticks in position causing high maintenance costs
Solution Approach 1:
The patent replaces the mechanical displacement float system with an optical measurement system. The float mechanism is substituted by optical sensors (such as laser sensors or cameras) that detect the liquid level through optical reflection or scattering principles, eliminating mechanical contact with the slurry and thereby eliminating mechanical wear and sticking issues while maintaining measurement precision.
Solution Approach 2:
The patent introduces an intermediary medium (such as a reflective surface or optical path) between the measurement system and the slurry. This intermediary allows optical signals to interact with the liquid level without requiring direct mechanical contact, enabling accurate level measurement while preventing the float from sticking or wearing out due to direct exposure to the abrasive slurry environment.
2Measurement precision
If pressure transmitter is used to measure slurry/pulp level, then level measurement is obtained, but pipes block up requiring constant purging and maintenance
Solution Approach 1:
The patent replaces the pressure transmitter system with an optical measurement system. Instead of using pressure sensors that require physical connection through pipes susceptible to blocking, the system uses optical sensors that measure level through electromagnetic radiation, eliminating the need for pipes and purging mechanisms while maintaining measurement accuracy and reducing maintenance requirements.
Solution Approach 2:
The patent introduces an optical intermediary (such as a reflective plate or optical window) that allows level measurement without direct penetration into the slurry flow path. This intermediary enables the measurement system to obtain level data without requiring pipes that can block, thereby eliminating purging requirements and reducing maintenance while preserving measurement precision.
3Measurement precision
If conductivity probe is used to measure slurry/pulp level, then level measurement is obtained, but build-up on probe causes insulating characteristic and probe ceases to function
Solution Approach 1:
The patent replaces the conductivity probe system with an optical measurement system. Instead of relying on electrical conductivity measurements that are disrupted by insulating build-up, the system uses optical sensors that detect level through light interaction, eliminating the dependency on electrical properties and thereby preventing failure due to insulating layer formation while maintaining measurement precision.
Solution Approach 2:
The patent introduces an optical intermediary (such as a reflective surface or optical path through a window) that allows level measurement without direct contact between the sensing element and the slurry. This intermediary prevents build-up on the sensing probe, maintaining reliable optical signal transmission and ensuring continuous operation without the insulating effects that plague conductivity probes.
4Loss of information
If human operator monitors froth density and level, then feedback is obtained, but cost is expensive and human error occurs
Solution Approach 1:
The patent replaces human operator monitoring with automated optical sensing systems (such as cameras or laser sensors) that continuously measure froth level and density. These systems provide objective, error-free measurements and automatic feedback to the control system, eliminating human error and reducing labor costs while maintaining comprehensive monitoring of froth parameters.
Solution Approach 2:
The patent implements automated feedback loops where optical sensors continuously measure froth level and density, and this data is automatically fed back to the control system for real-time adjustment of flotation cell parameters. This automated feedback mechanism eliminates the need for human operators to manually monitor and record data, reducing costs and eliminating human error while providing continuous, accurate feedback for process optimization.
5Measurement precision
If camera is used to detect froth overflow, then overflow detection is obtained, but prediction of froth collapse is not possible
Solution Approach 1:
The patent enhances the simple optical detection system with advanced optical sensors capable of measuring multiple parameters (level, density, texture, movement) simultaneously. These enhanced sensors can detect subtle changes in froth characteristics that precede collapse, enabling prediction capability while maintaining accurate overflow detection. The system processes multiple optical signals to derive both current state and trend information.
Solution Approach 2:
The patent implements a multi-parameter feedback system that continuously monitors froth level, density, and texture characteristics. By analyzing trends in these parameters over time, the system can predict froth collapse before it occurs and provide advance warning. This feedback mechanism maintains accurate overflow detection while adding predictive capability through analysis of changing froth properties.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system provides reliable, accurate, and autonomous measurement of substance levels and properties, reducing maintenance needs and operator intervention, and can operate effectively in harsh mining environments with varying ore complexities and reagents.
Implementation Method 1
A sensor system utilizing arrays of acoustic transducers that generate and receive signals to determine the levels and properties of substances in a flotation tank
Implementation Method 2
A sensor system utilizing arrays of acoustic transducers that generate and receive signals to determine the levels and properties of substances in a flotation tank, including a self-cleaning mechanism to prevent buildup and maintain accuracy
Data Source
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AI summary
A sensor (1) including at least one array (10), including a plurality of acoustic transducers (12); a controller (42) for controlling each transducer (12) to be selectively in a generation mode for generating an analysis signal, or a reception mode for receiving an analysis signal, and, for controlling the sensor (1) to perform scans of the at least one array (10), each scan having a plurality of scan steps, such that, during each scan step, at least one transducer (12) is in the generation mode and at least one other transducer (12) is in the reception mode; and, a processor (44) for processing one or more signals receivable from one or more of the controller (42), a transducer (12) in generation mode and a transducer (12) in reception mode to determine at least one characteristic from the one or more signals.